Farm Hand Stage Masteresvc000637.wic056u.server-web.com/manuals/4801-0151 Farm... · 2008-10-03 · Part No. 4801-0151 Rev 8-04 Farm Hand Stage Master 6 of 39 Var/Timer Percentage

Part No. 4801-0151 Rev 8-04 Owners Manual Farm Hand Stage Master

Farm Hand Stage Master Environmental Stage Controller

Hired Hand Manufacturing, Inc. 1733 Co Rd 68

PO Box 99 Bremen, Alabama 35033

Part No. 4801-0151 Rev 8-04 Farm Hand Stage Master Table of Contents

Table of Contents Section Title Page 1. Ratings and specifications ..............................................................................................................................3 2. Warnings ........................................................................................................................................................3 3. Limited Warranty ...........................................................................................................................................3 4. Introduction ....................................................................................................................................................4 5. Day to Day Operating Instructions .................................................................................................................5

5.1 Checking/Adjusting Temperatures, and Timer Percentages...................................................................5 5.2 Running Curtain Machines .....................................................................................................................7 5.3 Adjusting Stage On/OffPoints ................................................................................................................7

6. Program Mode ................................................................................................................................................8 6.1 Sensors For Display (PSd)......................................................................................................................8 6.2 Stage Parameters.....................................................................................................................................8

6.2.1 Stage Sensors (P1) ..........................................................................................................................9 6.2.2 Stage Mode (P2) .............................................................................................................................9 6.2.3 Stage Timer Settings (P3) ...............................................................................................................9 6.2.4 Minimum Runtime Percentage (P10) (Variable Stages Only)......................................................10 6.2.5 Motor Curve (P11) (Variable Stages Only)..................................................................................10

6.3 Curtain Parameters................................................................................................................................10 6.4 Cool Timer Settings (ON/OFF Stages Only).......................................................................................11 6.5 PC Compatible Network Parameters ....................................................................................................11 6.6 Sensor Calibration ................................................................................................................................12

7. Rarely Changed Settings ..............................................................................................................................12 7.1 Switch Settings .....................................................................................................................................13

8. Controller Installation and Setup ..................................................................................................................14 8.1 Installation ............................................................................................................................................14

9. Programming Examples................................................................................................................................15 9.1 Setting Stage OnPoints and OffPoints..................................................................................................15 9.2 Setting up Stage Modes, and Timer Status ...........................................................................................15 9.3 Setting Up Tunnel Control ...................................................................................................................15 9.4 Cool Timer Stage Operation.................................................................................................................16 9.5 Variable Speed Stage Operation...........................................................................................................17

9.5.1 Variable Speed Stage Operation (Variable Stage Model Only) ...................................................17 9.5.2 Progressive Cool Timer Option ....................................................................................................18

10. Maintenance..............................................................................................................................................19 11. Wiring Diagrams, Schematics, etc............................................................................................................19

11.1 FH Stage Master Layout.......................................................................................................................20 11.2 Connecting the Curtain Machines to the Controller .............................................................................21 11.3 Connecting Sensors to the Controller ...................................................................................................22 11.4 Connecting Stages in a Variable Controller or Controller with PCB 150 to a Relay Panel .................23 11.5 Connecting Stages in a Non-variable Controller or Controller with PCB 164 to a Relay Panel ..........24 11.6 Connecting AC Power to the Controller...............................................................................................25 11.7 Variable Speed Wiring .........................................................................................................................26 11.8 Variable Speed Wiring with External Hookup.....................................................................................27 11.9 Connecting the Stage Master to a Data Shuttle ....................................................................................28 11.10 Connecting the Stage Master to a Series or Parallel Alarm..............................................................29

12. Program Reference ...................................................................................................................................30 13. Error Codes...............................................................................................................................................33

13.1 Descriptions ..........................................................................................................................................33 13.2 Possible Solutions.................................................................................................................................33

14. Temperature vs. Sensor Resistance Table ................................................................................................35 15. Program Parameter Listing .......................................................................................................................36 16. Error Code Listing ....................................................................................................................................37 17. Curtain Movement Time (sec.) Vs. Distance (inches/cm.).......................................................................38 18. Program Data Sheet ..................................................................................................................................39

Part No. 4801-0151 Rev 8-04 Farm Hand Stage Master 3 of 39

1. Ratings and specifications • 115/230 Volts (Depending on switch position.) • 50/60 Hz. • 12 Amps per stage. • 12 Amps per variable speed stage. • 8 Amps per curtain machine. • Room must be kept above 32°F/0°C.

2. Warnings Warning!

Before connecting power to the machine, be sure to check the position of the voltage selector switch located next to the transformer on the relay board.

Improper positioning of this switch will cause system failure.

Warning!

When this controller is used in a life support heating and ventilation system where failure could result in loss or injury, the user should provide adequate

back-up, or accept the risk of such loss or injury!

3. Limited Warranty All products are warranted to be free from defects in material and workmanship for a period of one year from the date of purchase if installed and used in strict accordance with the installation instructions. Liability is limited to the sale price of any products proved to be defective or, at manufacturers option, to the replacement of such products upon their return. No products are to be returned to the manufacturer, until there is an inspection and/or a return-goods authorization (RGA) number is issued. All complaints should be directed first to the authorized distributor who sold the product. If satisfaction is not obtained or the name of the distributor is not known, write the manufacturer that appears below, directed to the attention of Customer Service Manager. This limited warranty is expressly in lieu of any and all representations and warranties expressed or implied, including any implied warranty of merchantability or fitness for a particular purpose. The remedy set forth in this limited warranty shall be the exclusive remedy available to any person. No person has authority to bind the manufacturer to any representation or warranty other than this limited warranty. The manufacturer shall not be liable for any consequential damages resulting from the use of our products or caused by any defect, failure or malfunction of our products. (Some areas do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.) This warranty gives you specific legal rights and you may also have other rights that vary from area to area. Warrantor: Hired-Hand Manufacturing, Inc. 1733 Co. Rd. 68 PO Box 99 Bremen, Alabama 35033


4. Introduction There are four models of the Stage Master controllers that are listed below:

Farm Hand Stage Master 8 without Variable Speed Farm Hand Stage Master 8 with Variable Speed Farm Hand Stage Master 12 without Variable Speed Farm Hand Stage Master 12 with Variable Speed

The only distinctions between the 8 Stage models and the 12 Stage models are the number of stages and the face pad. The following figures show the differences in the face pads.

The Farm Hand Stage Master Stage Controller is designed to be one of the simplest controllers on the market to operate, but to also be one of the most powerful. The Stage Master has four main regions on the facepad that you need to be concerned with. First is the main display. This section includes the main display, and four green LED’s which tell what the display is

Main Display

Control Buttons

Display Indicators

Stage Status Indicators

Variable Stages(Depending On Model)

Curtain Machine Controls

Stage Buttons

Notice: If the Farm Hand Stage Master is a Variable Speed Model, then stages 1 & 2 are the Variable Speed stages.

Main Display

Control Buttons

Display Indicators

Variable Stages(Depending On Model)

Stage Status Indicator

Curtain Machine Controls

Stage Buttons

Stage Master 8

Stage Master 12


indicating. If the green light beside “Room Temperature” is lit, then the display is showing the display option chosen in the Program Mode under the parameter PSd. Refer to Section 6.1 for an explanation of the PSd parameter. Later in this manual you will learn how to see the other three parameters. On the left hand side of the controller face you will see the stage displays. When the controller is operating you will see the OnPoint of each stage (the temperature the stage will turn on). Next to the stage indicators, is a button with the number of the stage printed on it. You will press this button to set your on and OffPoints for that stage. (Stage OnPoints and OffPoints are discussed later in the manual.) The blank white region is for you to label your equipment such as (front heat, back heat, sidewall fans, etc.). Finally, there is a small red LED on the bottom right of this white region. This is the stage status indicator. This light will be lit if the stage is on, and will flash on and off if it is running because it is on a timer. Just below the main display on the right hand side of the controller is the control button region. This region has three buttons, Mode, +, and -. You will learn the use of these three buttons later in the manual. Finally, on the bottom right hand side of the controller is the curtain machine control region. This region includes an Automatic/Manual switch, and an Open/Off/Close switch for each machine.

5. Day to Day Operating Instructions This section of the manual will give you all you need to know about the day to day operation of your controller.

5.1 Checking/Adjusting Temperatures, and Timer Percentages When no one has pressed a button for over one minute, the display will automatically show “Room Temperature”. To see the outside temperature, press the button labeled “Mode”. This button is located in the center of the controller facepad. When you press the button, watch the green LED’s beside the main display. Whichever LED is lit is the parameter you are viewing. You can easily see “Outside Temperature”, “Var/Timer Percentage”, and “Target Temperature”.

Room Temperature The temperature read by the sensor(s) chosen in the Program Mode under the parameter PSd. Refer to Section 6.1 for an explanation of the PSd parameter.

Outside Temperature The temperature read by the sensor located outside the house. (Sensor 4) While displaying the Outside Temp, the controller will also display the temperatures read by sensors 1, 2, & 3 in the corresponding stage displays. The remaining Stage Displays will be blank at this time.

Room TempOutside TempVar/Timer PctTarget Temp

Outside Temp displays the outside temperature (Sensor 4).

Stage Status Indicator LED

Stages

1

2

3

Displays reading of Sensor




Var/Timer Percentage The Var/Timer percentage parameter can be used to set variable speed and/or runtime percentage depending on the model of the Farm Hand Stage Master. Variable Speed refers to the increase or decrease of fan speed as regulated by the controller based on temperature. For example, a Var/Timer Pct. set to 50 means that a fan will run at 50% of its maximum speed at a particular temperature. Runtime percentage refers to the percentage of the timer cycle that a stage on a timer will run. For example, if the Var/Timer Pct. is set for 30, and your timer cycle is set for 10 minutes, the timed stages will run for 3 minutes out of every 10 minutes (i.e. 30% of the timer cycle). There are two models of the Farm Hand Stage Master Controller. On the Non-variable speed model, this setting refers to the Runtime percentage for any of the stages that are on the system timer. On the Variable speed model, this setting is used to set the minimum speed for stages 1 & 2 and also the Runtime percentage for any of the remaining ON/OFF stages that are on the system timer. Please note your model. You can determine the model by comparing the main display sequence to that described in the following diagrams. Non-variable Speed Model - (Runtime Percentage) The Var/Timer Pct. parameter sets the Runtime percentage of all stages that are placed on a timer (See Section 9.2). The value of the Var/Timer Pct. in the main display refers to a Runtime % which can be set to values between 0 and 100 using the "+" and "-" buttons. When you step through the main display parameters, notice the stage status indicators. As the Mode button is pressed, a Var/Timer Pct. value will appear in the main display, and stages affected by this setting will have stage status indicators lit.

Variable Speed Model - (Minimum Speed %) On the variable speed model, this setting allows you to program three parameters: the Minimum speed % for stage 1, the Minimum speed % for stage 2, and the Runtime % for the remaining ON/OFF stages. If using the variable stages as progressive cool timer stages, this setting becomes the Minimum runtime % instead of the Minimum speed %. (Refer to Section 9.5.2 for more discussion on this option). As you step through the main display and you get to the Var/Timer Pct. setting, notice the stage status indicators. These indicators show which setting you are programming. The Var/Timer Pct setting is displayed as shown in the following diagram.

Non-variable Speed Model (Parameter selection sequence)


Stages

Press any stage button to set On/OffPoints. Adjust value with + and - buttons.

Stage Button

Target Temperature The temperature the system tries to maintain. To adjust these settings, press the mode button until you see the setting you want to adjust, then use the + button to raise the value, and the - button to lower the value. When you are finished setting a new value, either press the mode button again, or do nothing, and the system will return to normal operation within a few seconds.

5.2 Running Curtain Machines Under normal circumstances the machines should be left in automatic. This way, if the controller needs to open the curtains, it will open them. If, however, you want to open or close them for any reason do the following. 1. Find the switches for the machine you want to run, and check that the Open/Off/Close switch

is in the off position. This makes sure that the machine does not turn until you want it to. 2. Place the Automatic/Manual switch for that machine in the “Manual” position. 3. To open the machine place the Open/Off/Close switch to the position marked “Open”. 4. To close the machine place the Open/Off/Close switch to the position marked “Close”. 5. Finally when you are finished positioning the machine, place the switch back into the “Off”

position. Note: "Off" position is between "Open" and "Close". 6. When you are ready for the controller to take over control of the curtain, place the

Automatic/Manual switch in the automatic position.

5.3 Adjusting Stage On/OffPoints If you decide that a fan stage comes on too soon, or waits until temperature is too high to come on, you can easily adjust that setting. To adjust the stage OnPoint, press the numbered stage button one time. The individual stage display will flash, and the main display will flash between “On” and the Target Temperature. Use the + button to raise the value in the individual stage display until you see the correct temperature, or the - button to lower the value until the stage OnPoint is where you want it. When you are finished setting a new value, press the individual stage button again and the main display will read “Off” and flash the target

Variable Speed Model (Parameter selection sequence)


temperature. Use the + and/or - buttons until the correct setting shows in the individual stage display. Notice that as you press the stage button the first time, all of the individual stage displays show their stage’s OnPoints. Only one stage will flash this reading. When you press the + and/or - button, you will only adjust that particular stage's value. To adjust another stage, press that stage’s button. When you have finished setting your stage on/OffPoints press the individual stage button once more, and the system will not flash any stage displays, and the main display will read a steady value. Your controller is now operating normally again.

Note: In this manual, a stage's OnPoint parameter is referenced as (ON). A stage's OffPoint parameter is referenced as (OFF). For Variable stages, the Minimum OnPoint is the value of the (OFF) parameter. The Maximum OnPoint is the value of the (ON) parameter

6. Program Mode Settings that are usually set up once per growout, or maybe even just for summer or winter are referred to as program parameters and are accessed by taking the controller to program mode. Some examples of these settings are Curtain Runtime, Stages on Timers, and Sensor Calibration. To get to program mode, press and hold the “Mode” button for five seconds. When the controller has entered program mode, the main display will flash between “PSd” and the value of this parameter. The “PSd” is known as a parameter number. All the program items for the controller have a parameter number assigned to them. The numbers are listed in the section called “Program Reference” in the back of this manual with a short description of each parameter. When in program mode, you change the current parameter by using the + and - buttons as needed. When you have finished with the current setting, press the “Mode” button to move to the next parameter.

6.1 Sensors For Display (PSd) The user is given the choice as to what he/she wants to display for Room Temp. The choice is made in Program Mode under the parameter PSd. The following is a list of choices: PSd = Room Temperature Display 100 = Sensor 1 020 = Sensor 2 120 = Average of Sensors 1 & 2 003 = Sensor 3 103 = Average of Sensors 1 & 3 023 = Average of Sensors 2 & 3 123 = Average of Sensors 1, 2, & 3

6.2 Stage Parameters The following parameters are used to program each stage on the Farm Hand Stage Master. Through these parameters, the user has complete control over the operation of each stage. The following sections explain each parameter in detail. P1 = Stage Sensors P2 = Stage Mode P3 = Stage Timer Settings P10 = Minimum Runtime Percentage (Variable Speed Stages Only) P11 = Motor Curve (Variable Speed Stages Only)


6.2.1 Stage Sensors (P1) A stage can be programmed to run off of any sensor or combination of sensors. The following is the list of P1 options: P1 = Stage Sensors 100 = Sensor 1 020 = Sensor 2 120 = Average of Sensors 1 & 2 003 = Sensor 3 103 = Average of Sensors 1 & 3 023 = Average of Sensors 2 & 3 123 = Average of Sensors 1, 2, & 3

6.2.2 Stage Mode (P2) The Farm Hand Stage Master is a very intelligent controller, therefore, it needs to not only know whether this is a heating or cooling stage but also what type of cooling stage. The Farm Hand Stage Master reacts not only to temperature but also curtain position. This feature allows the grower to program the cooling stages to work exactly like he wants them to without the expense of hard wiring through relays and limit switches. This feature allows the Farm Hand Stage Master to better react to the environment. Any Stage can be programmed to be one of the following:

1 = Heat This mode allows the equipment to operate when room temperature is below the OnPoint for the stage, and the curtains are closed.

2 = Cool Stir This mode setting allows the cool stage to run whether the main curtain is open or closed. The only time that this mode will not run is during tunnel mode.

3 = Cool Negative This mode setting only allows the cooling stage to run if the main curtain is closed, hence the name Negative. This stage will not run if the controller is in tunnel mode.

4 = Cool Negative Tunnel This mode setting works exactly like the Cool Negative setting except it will run if the controller goes into tunnel mode. This stage is sometimes referred to as a transitional stage. In other words, it operates before it goes into tunnel and also during tunnel.

5 = Cool Tunnel This mode setting only works when the controller is in tunnel mode.

6.2.3 Stage Timer Settings (P3) The Farm Hand Stage Master is equipped to satisfy any of your minimum ventilation needs for regular runtime timers, to cool timers, to progressive timers.

00 = No Timer Select 0 for the timer setting if you do not want the stage to be on a timer.

Important: In the following descriptions, many references are made to the Main Curtain (Unit 1). If you do not have a Main Curtain or do not wish to use the auxiliary connection as shown in Section 11.2, you must place a jumper across the signal terminals for Unit 1. This manipulates the controller into thinking the main curtain is closed. In turn, this allows the heat and negative stages to operate.


01 = Runtime Timers Any one of the On/Off stages can be placed on the system timer by placing a "1" in parameter 3 (P3) of the stage. By doing this the stage will operate off of the system timer while the temperature is below the stage's OnPoint. Once the temperature reaches the stage OnPoint, the stage will come on full time.

02 = Cool Timers ON/Off Stages Any one of the On/Off Stages can be placed on a cool timer. By doing this the stage will operate off the system timer only while the temperature is above the stage OffPoint (OFF). Refer to Section 9.4 "Cool Timer Stage Operation" for proper setup. Variable Stages Any of the variable stages can be placed on a cool timer. By doing this the stage will be placed on the system timer all the time. It will run full speed for a certain percentage of time which is set in Var Timer/PCT. This percentage will progressively increase as the temperature rises above the minimum OnPoint setting (OFF). Refer to Section 9.5 "Variable Speed Stage Operation" for proper setup.

6.2.4 Minimum Runtime Percentage (P10) (Variable Stages Only) This setting is the percentage of the system timer that the variable stage will run at minimum speed if the stage sensor's temperature is below the Minimum OnPoint (OFF) for the stage.

6.2.5 Motor Curve (P11) (Variable Stages Only) The controller is programmed to operate single phase or three phase fan motors at their optimum performance levels. Select the correct motor curve parameter (P11) for your particular application from the following table.

6.3 Curtain Parameters This controller runs 1 or 2 curtain machines independently. No additional resources – including external timers – are necessary. The curtain machines run off a common cycle timer and run timer, however they can use separate sensors. The sensor selection is made via a switch located on the inside of the front cover of the machine. This switch causes the machines to either operate together or independently. If they are operating independently, unit 1 always uses sensor 1 and unit 2 uses sensor 2. A brief overview of the programmable parameters for the curtain machines follows:

Note: Parameters P20-P24 are only used when using the main curtain to naturally ventilate the building.

Curve Conditions 0 This curve is optimized for use with Hired Hand’s line of Funnel Flow Fans that are 24” or less. Also, line

voltage must be Single Phase. 1 This curve lends itself better to operation of 36” fans. The power distributed at each percentage is somewhat

greater than that of curve 0. Therefore, the speed will be a little greater than that of curve 0 2 This curve is for 3-Phase systems. Its purpose is to shift the voltage curve to give a much higher power from

the varied phase. Conditions that would warrant the use of this curve is a variable speed fan that varies a great deal from 100% speed to 95% speed.

3 This curve is for 3-Phase systems. Its purpose is to shift the voltage curve to give much less power from the varied phase. Conditions that would warrant the use of this curve is a variable speed fan that varies very little from 100% speed to 5% speed.

4 This curve is for use with Hired-Hand’s newest Emerson fan motor. These motors are typically used on fans that are 24” or smaller.


P20 -- Cycle Time The controller looks at all parameters and decides whether or not to move the curtains occasionally. This parameter determines how often this occurs. Valid settings are 1 to 10 minutes.

P21 -- Run Time When the controller determines that curtains need to run open or close, this setting determines how long they run. Valid settings are 1 to 240 seconds.

P22 -- Initial Run Time When the controller determines that the curtains should run open and senses that they are closed, it uses this parameter for the ‘first’ run. This setting is used to allow the curtains to open enough on the first run to guarantee adequate ventilation. Valid settings are 1 to 240 seconds.

P23 -- Degrees above target for Unit 1 Generally a grower would like to give his variable speed and/or first stage fans an opportunity to ventilate the building before starting curtains open. Thus, when the curtains do come down, they will most likely stay down for a fair period of time. This setting allows the user to do that. Valid settings are: 0 - 25.

P24 – Degrees above target for Unit 2 Occasionally, a grower may want one curtain sidewall to drop before the other to try to avoid large temperature swings. This setting allows for this to happen. Note: If you would like both curtain units to always react together, you must set P23 = P24.

P25 – Tunnel OnPoint This is the sensor 4 temperature at which the controller will enter tunnel mode. Only applicable when tunneling on outside temperature.

P26 -- Tunnel OffPoint This is the sensor 4 temperature at which the controller will exit tunnel mode. Only applicable when tunneling on outside temperature.

P27 -- Close Override (Degrees Below Target) This setting provides the grower a temperature at which to override the curtains closed. The setting represents degrees below target at which time the curtains will begin closing regardless of the cycle. The setting allows the user to anticipate quick temperature drops to help maintain a stable inside temperature. Valid settings are 1-25.

6.4 Cool Timer Settings (ON/OFF Stages Only) The following two settings allow the user to set the Runtime range for their cool timer stages. These settings apply to the cool timers on the On/Off stages only.

P70 = Cool Timer Maximum Percentage This sets the maximum Runtime percentage that a cool timer stage can operate.

P71 = Cool Timer Minimum Percentage This sets the minimum Runtime percentage that a cool timer stage can operate.

6.5 PC Compatible Network Parameters This option requires Hired-Hand’s Farm Manager Software. The controller has 3 functions which are used to set it up on the Hired-Hand PC compatible inter-controller network (HH.Net). These are:

P40 – HH.Net Address HH.Net allows you to connect up to 32 controllers on a single communications port of your personal computer (PC). In order for the computer to recognize the communications from the controllers, each controller must have a unique address. For example: If you have two Stage Master, and two Power Vents you would


need to set the first Stage Master to be address 1, the second Stage Master to address 2, the first Power Vent to address 3, and the second Power Vent to address 4. Valid settings are: 1 - 32. (You do not have to address the controllers in any particular order.)

P41 -- Version Number This is not settable. It is the version of controller software.

P42 -- Controller Type This is not settable. It is a unique number that allows the network software (Farm Manager) to know the type of controller.

6.6 Sensor Calibration The Stage Master has 4 sensors that may be calibrated. The parameter(s) for calibration are PSx with x being the sensor number. The sensor temperature reading is alternately displayed along with the parameter number. You should never attempt to calibrate a sensor more than 8 degrees. If you have a setting that far out of range, it indicates that there is a problem that should be corrected.

PS1 - Calibrate Sensor 1 This reading can be changed by pressing the + or - button until the desired reading is displayed.




7. Rarely Changed Settings Settings which are rarely, or never, changed are found on two banks of switches located inside the front panel of the controller. The left hand bank of switches is for Tunnel Control, and the right hand bank of switches controls the status of the controller. When a switch is up it is ON, when a switch is down it is OFF. The functions of the switches are as follows:

HIRED-HANDR

V FAN IN V FAN OUT

# 1

Farm Hand Stage Master

Program Switch Banks


7.1 Switch Settings

Tunnel Switches

SWX 1 - Tunnel On/Off This switch is used to enable or disable the tunnel mode of the controller. When this switch is in the OFF position, the controller will not go into tunnel for any reason.

SWX 2 - Tunnel On Stage This switch tells the controller whether it is tunneling off of the lowest programmed tunnel stage or if it is tunneling off of outside temperature. If this switch is OFF, the controller will use the “Tunnel OnPoint” setting for entry into tunnel.

SWX 3 - Power Ventilate This switch indicates whether this is a power ventilated house or a natural ventilated house. If it is a power ventilated house the controller will leave the inlet curtain closed until tunnel mode is entered. This switch must be set to ON if you have a Power Ventilated house.

SWX 4 - Not used at this time This switch may be used in the future by Hired-Hand to add greater functionality/flexibility to the controller. The switch position has no effect on the operation of the controller.

Status Switches

SWX 1 - Lock This switch is used to lock the controller. When it is on, the user may change settings such as target temperature and minimum speed/timer percentages but they can not change the settings in program mode. If the switch is set to ON the program settings are locked.

SWX 2 - Fahrenheit/Celsius This switch toggles between Fahrenheit and Celsius operation. If the switch is set to ON the controller will read the sensors as Fahrenheit. (Note: If you change this switch, you will have to reset your tunnel OnPoints and OffPoints and your Target Temperature.)

SWX 3 - 5/10 minute timer This switch selects between a 5 and 10 minute system timer. If the switch is ON, the timer is 10 minutes.

SWX 4 - Sensor 3 Active This switch turns off sensor 3. If the switch is off, sensor 3 is turned off. Note: This is used to disable the sensor in the back half of a half house brooding situation. This way the low temperature reading does not affect the temperature readings for the rest of the house. Just be sure that sensor 3 is placed in the non-brood end of the house. If the switch is ON, sensor 3 is used.

SWX 5 - Curtains On Separate Sensor This switch is used to choose whether the curtain machines operate off the same sensor or if they operate independently. If the switch is ON, the curtains are independent with curtain 1 running on sensor 1, and curtain 2 running on sensor 2. If the switch is OFF, both units operate on the average of all the inside sensors.




SWX 8 - Program ‘A’ or ‘B’ This switch is used to toggle between 2 preset programs. This could be used to store separate summer/winter programs for instance. The ON position is for Program A, and the OFF position is for Program B.

8. Controller Installation and Setup

8.1 Installation Tools Required

Mini Screwdriver Standard Screwdriver Wire Strippers

Installation Instructions

1. Unpack system, and check that all components are present. 1 Farm Hand Stage Master 1 Installation Kit 1 Fuse Kit 4 Sensors 1 Manual

2. Hang Farm Hand Stage Master with four screws.

3. Make sure all power supplies are disconnected before breaking any wires, or reaching into the enclosure.

4. Open Stage Master and find all connections. Refer to wiring diagrams in back of this manual.

5. Run sensors out to locations inside the house. (Outside sensor should be installed outside the house.) Be sure that the sensors are in a safe location, free from any temperature influences (direct sunlight, water, etc.) Use care when securing sensor wires so that you do not cut the wire, Any short, or break in the wire will cause improper sensor operation.

6. Connect each sensor to its appropriate terminals inside the enclosure. (See wiring diagrams in the back of this manual.)

7. Connect wires from stage terminals to the contactor panel, or relay box. See wiring diagrams for locations of terminals.

8. Hookup three wire connections from Stage Master board to curtain machines. See wiring diagrams for locations of terminals.

9. CHECK THE POSITION OF THE VOLTAGE SELECTOR SWITCH. Connect the wires for 120/240V power to the terminals specified in the wiring diagram.


9. Programming Examples When following these examples, you will need to refer to the Program Reference section to see which options are available for each of the parameters (P1, P24, etc.).

9.1 Setting Stage OnPoints and OffPoints OnPoint, and OffPoint are easily set by pressing the numbered button on the left hand side of the front panel. When you press one of the stage buttons, the main display will show “ON”. Then use the + and - buttons until you see your setting in the individual stage display. (The stage display you are adjusting will flash until you press the stage button again.) If you want to program all the stages OnPoints, you may do so by clicking on another stage’s button, then using the + and - buttons. Press the stage button again, and the main display will show “OFF” adjust the OffPoint just like you did the OnPoint. When you are finished, press the stage button again, and you will return to normal operation. Repeat this process for each of the twelve stages.

9.2 Setting up Stage Modes, and Timer Status There are three parameters used in programming any stage. They are P1-P3. The following is an overview of how to program a stage:

1. Enter Program Mode by pressing and holding the Mode button for 5 seconds until P1 is displayed, and the stage 1 display begins to flash. This parameter selects the sensor(s) that this stage watches for on/off operation.

2. Select the stage you want to program by pressing the stage button (next to the stage display.)

3. Press the + or - button until the desired sensor is displayed. 100= sensor 1; 020 = sensor 2; 120 = Average of Sensors 1&2; 003 = Sensor 3; 103 = Average of Sensors 1 &3; 023 = Average of Sensors 2 & 3; 123 = Average of Sensors 1,2, & 3.

4. If you want to program more stages sensors, press the next stage’s button, and repeat step 3.

5. Press the Mode button again and P2 is shown. This parameter selects what mode the stage operates as.

6. Press the + or - button until the desired mode is displayed.

7. If you want to program more stages modes, press the next stage’s button, and repeat step 6.

8. Press the Mode button until P3 is displayed. This parameter allows you to put a stage on the system timer (5 or 10 minutes).

9. Press the + or - button until the desired setting is displayed.

10. If you want to program more stages stage timer settings, press the next stage’s button, and repeat step 9.

11. Exit Program Mode by pressing the Mode button until after PS4 has been displayed or wait 1 minute.

9.3 Setting Up Tunnel Control

Note: If you do not want the controller to ever enter tunnel mode just make sure that the Tunnel On/Off switch is in the off position and you can ignore this section.

The Stage Master is a very versatile tunnel controller. It provides the grower with many different ways to tunnel based on the layout of the house. It also provides two different ways of initiating tunnel mode. The following are some tips and examples of setting up this controller to tunnel your house appropriately.


1. The first step in setting up your tunnel house is to configure the stages that you want as your cool tunnel stages. If some stages need to operate in tunnel mode and in normal mode, then program these stages to be cool negative tunnel stages. See the Program Reference section in the back of this manual for more information on the operation of various stage modes.

2. The next step in setting up your tunnel house is determining how your controller should operate while out of tunnel mode. In other words, does your house always power ventilate or does it naturally ventilate using curtain sidewalls. If it is a power ventilated house you must set the Power Ventilate switch (Tunnel bank SWX-3) in the on position.

3. The last step in setting up your tunnel house is determining how you would like to initiate tunnel mode. You can initiate tunnel mode by outside temperature or by your lowest programmed cool tunnel stage. The lowest programmed cool tunnel stage is determined by the lowest OnPoint. If you would like to tunnel based on outside temperature you must set the Tunnel On Stage (SWX-2) switch to off. You can then set the temperature at which you would like to enter tunnel mode at P24 and the temperature at which you would like to exit tunnel mode at P25. Otherwise, set the Tunnel On Stage (SWX-2) to on.

The following is a brief description of how the tunnel would work in each of the situations.

Tunneling on outside temperature in a naturally ventilated building When the outside temperature rises above the Tunnel OnPoint (P25), the controller will shut down all stages and begin to close the main curtain and open the inlet curtain. After 1 minute has passed, the controller makes sure that the inlet is open. If there is no error condition, the controller will begin waiting for the main curtain to close. If the controller does not see the main curtain closed after 12 more minutes, it will abort tunneling, and sound the alarm. Once the controller recognizes that the main curtain is closed, it will then allow the other cool tunnel and cool negative tunnel stages to come on. Once the temperature drops below the Tunnel OffPoint (P26), the controller will open both the inlet and the main curtain fully and return the stages to normal operation immediately.

Tunneling on a stage in a power ventilated building As soon as the lowest programmed Cool Tunnel stage comes on, the controller opens the inlet curtain and leaves all Cool Negative Tunnel and Cool Tunnel stages on. When the temperature begins to fall and the lowest programmed Cool Tunnel stage turns off, the controller will close the inlet fully and return the stages to normal operation immediately.

Tunneling on outside temperature in a power ventilated building The controller reacts in the same way as in the previous example, except it uses P25 and P26 to enter and exit tunnel. For proper operation in a house without a curtain sidewall, you must jumper the curtain closed switches on the main curtain together.

Note: If you are using a main sidewall curtain, it must run at a speed where it can go from fully open to fully closed in less than 13 minutes. If not, the controller will not operate properly as tunnel.

9.4 Cool Timer Stage Operation On the Farm Hand Stage Master any of the ON/OFF can be placed on a cool timer. A cool timer stage will come on and run at the timer percentage whenever temperature is above it’s OffPoint (Off), and its timer percentage will increase as temperature rises. The following graph shows how you can vary this percentage. Refer to Graph 1 and Table 1. The stage is placed on a cool timer by setting P3=2. A Cool Timer stage always varies its runtime based on the stage's temperature and it’s ON and OFF settings. In this example, the OffPoint is set to 80ºF (OFF=80), and the OnPoint is set to 86ºF


Setting Stage Sensor Stage Mode Stage Timer OffPoint OnPoint Cool Timer Max %

Cool Timer Min %

Parameter P1 P2 P3 OFF ON P70 P71 Value 10 02 02 80 86 90 50 Option Sensor 1 Cool Stir Timer ON Minimum

OnPoint Maximum OnPoint

Maximum Runtime %

Minimum Runtime %

(ON=86). The stage will not run if the temperature is below the OffPoint, as shown in Graph 1. When the temperature reaches the OffPoint, the stage is placed on the system timer. To enhance temperature control, the Runtime percentage of a cool timer stage can be varied. The percentage of the Runtime that the cool timer stage is ON can be varied when the temperature is between the OffPoint and the OnPoint by setting parameters P70 and P71. In this example, the Minimum Runtime percentage is 50%, as set by P71 = 50. The Maximum Runtime percentage is 90%, as set by P70 = 90. When the temperature reaches 80ºF the stage runs for 50% of the Runtime period (2-1/2 minutes if the system timer is set for 5 minutes, or 5 minutes if the system timer is set for 10 minutes). As the temperature increases, the Runtime percentage of the stage progressively increases up to the Maximum Runtime percentage of 90% when the temperature reaches 86ºF. Above 86ºF, the Runtime percentage remains constant at 90%.

Table 1 Example Of Cool Timer Stage Operation Brief Description Of Cool Timer Stage Operation As you can see, a stage will be placed on the system timer once the temperature rises above 80ºF (OFF) and will start running 50% (P71) of the time. If the temperature continues to increase then the run time percentage will also increase toward 90% (P70).

9.5 Variable Speed Stage Operation Depending on the Farm Hand Stage Master model, you have 0 or 2 variable stages. The Variable stages can be used in one of two ways: Variable Speed or Progressive Cool Timer. The two options are selected by the parameters P3. The following sections explain the operation of both options.

9.5.1 Variable Speed Stage Operation (Variable Stage Model Only) Note: This option applies to stages 1 and 2 of the Variable Stage Farm Hand Stage Master. The variable speed option (P3=0) allows the user to configure the variable stage to vary the speed of the fan for their minimum ventilation needs. The following explains the setup and operation. In this case, the stage timer setting is P3=0 to indicate variable speed operation. The Minimum OnPoint (OFF) is set for 75ºF, and the Maximum OnPoint (ON) is set for 80ºF. This establishes the temperature range (75º-80º) over which the speed is varied. The variable speed percentage is set by the "Var/Timer

75 80 85 90

Run

time

Per

cent

age

Graph 1 ON/Off Stages

86ºF OnPoint

90

50 80º F

OffPoint

Temperature (F)


Pct." parameter as described in Section 5.1. In this example, Var/Timer Pct. is set to 50%. The Minimum Runtime percentage is set to 40% (P10=40). Below 75ºF, a fan connected to the variable speed stage will run at 50% speed for 40% of the system timer (either 2 minutes for a 5 minute timer, or 4 minutes for a 10 minute timer). When the temperature reaches 75ºF, the fan will run at minimum speed (50%) continuously. As the temperature increases, the fan speed progressively increases from 50% up to 100% at 80ºF. Above 80ºF, the fan runs continuously at its maximum speed.

Table 2 Example Of Variable Speed Fan Control Brief Description Of Variable Speed Fan Control From the graph, you can see that at 78°F, the variable speed fan will run at 70% of maximum speed. Below 75°F the variable speed fan will run at it’s minimum speed, for the minimum timer percentage (P10). Above 80°F the variable speed fan will run at 100% continuously.

9.5.2 Progressive Cool Timer Option The progressive Cool Timer operation varies the Runtime percentage while keeping the fan speed constant. Refer to Graph 3 and Table 3. The stage timer is set to ON (P3=2). In this case, the stage timer setting is P3=2 to indicate progressive cool timer operation. As in the previous example, the Maximum OnPoint is set to 80ºF (ON=80), and the Minimum OnPoint is set to 75ºF (OFF=75). The Runtime percentage is progressively varied over this temperature range from 75º to 80º. The "Var/Timer Pct." parameter, which in this case refers to the stage's minimum runtime percentage, is set to 50 (See Section 5.1) At 75ºF and below, the stage will operate at full speed on a system timer running at its minimum runtime percentage (Var/Timer Pct. = 50). As the temperature increases above 75ºF so does the stage's runtime percentage. Once the temperature rises above 80ºF, the stage will run continuously.

Per

cent

Of R

untim

ePe

rcent

OfFu

ll Spe

ed

100

50

50

100

76 78 807775 79

TEMPERATURE (F)

Graph 2 Variable Speed Fan Minimum OnPoint Minimum Speed Maximum OnPoint

Maximum Speed

Setting Stage Sensor

Stage Mode

Stage Timer

Minimum OnPoint

Maximum OnPoint

Minimum Runtime %

Motor Curve

Var/Timer Percentage

Parameter P1 P2 P3 OFF ON P10 P11 N/A Value 10 02 00 75 80 40 0 50 Option Sensor 1 Cool Stir No Timer Fan begins

Varying Speed

Fan begins Maximum Speed

Runtime 40%

Standard single phase

Refer to Section 5.1


Brief Description of Progressive Cool Timer Option As you can see from graph 3, as the temperature increases above the Minimum OnPoint, (OFF=75ºF) the Runtime % progressively increases until it reaches 100% at its Maximum OnPoint (ON = 80ºF). When using this option, it is not necessary to set P10 or P11 for the stage. These parameters only apply to variable speed operation.

10. Maintenance Check the calibration of your sensors at least once per quarter. To do this, you will need to have two persons: one at the sensor with a trusted thermometer, and one at the controller to set the sensor to the proper setting.

11. Wiring Diagrams, Schematics, etc. All wiring connections for stages, curtain machines, variable speed fans, and curtain sensors inside the controller are made without terminals on the end of the wire. To make the connection, strip about ¼” of the insulation off the wire, and follow the diagram below.

1. Insert a small screwdriver into either the hole shown in the diagram.

2. Insert the stripped end of the wire into the hole shown in the diagram.

3. Remove the screwdriver, and tug slightly on the wire to check that it is snug.

Warning! Do not connect more than 12 amps of load to any one stage. The Variable Speed

Circuit will carry up to 12 amps.

100

Per

cent

Of R

untim

ePe

rcent

OfFu

ll Spe

ed 50

50

100

76 78 807775 79

Graph 3 Progressive Cool Timer Option

Maximum OnPoint

TEMPERATURE (F)

Minimum OnPoint

Table 3 Progressive Cool Timer OptionSetting Stage

Sensor Stage Mode

Stage Timer

Minimum OnPoint

Maximum OnPoint

Minimum Runtime %

Motor Curve

Var/ Timer %

Parameter P1 P2 P3 OFF ON P10 P11 N/A Value 10 02 02 75 80 N/A N/A 50 Option Sensor 1 Cool Stir Timer ON Stage begins

varying Runtime

Stage runs continuously

N/A N/A Refer to Section 5.1


11.1 FH Stage Master Layout

HIRED-HAND

R

V FAN IN

V FAN OUT

# 1

Pow

er T

o

HH

Net

PC

Net

wor

k

AC P

ower

11

5/23

0 V

Sele

ctor

Sw

itch

FAR

M H

AND

STA

GE

MAS

TER

Al

arm

C

onne

ctio

ns Po

wer

Fro

m

Stag

es 3

-12

Cur

tain

Mac

hine

Con

nect

ions

Pr

ogra

m S

witc

h Ba

nks

Pow

er F

rom

St

ages

1-2

Stag

es 3

-12


11.2 Connecting the Curtain Machines to the Controller Note: If you are tunnelling with this controller, the inlet machine must be

connected to “Curtain 2”. Your main curtain should be connected to “Curtain 1”

PowerTrak #1ClosedSignalCom OpenClose

PowerTrak

AUXSWITCH CONTROLLER AC IN

HOT

NEUT

.

LOW

ER

GND

.

HOT

OUT

CLO

SE INO

PEN

IN

COM

UPPE

R

Inset A

Inset A

V FAN IN V FAN OUT


11.3 Connecting Sensors to the Controller

The controller has a switch for disabling Sensor 3. If you use a half house brood layout, you need to place Sensor 3 in the non brood section of the house, and disable Sensor 3 by turning switch 4 of the Status Switch Bank to off. (See “Rarely Changed Settings” for more information.)

Black

White

Shield

V FAN IN V FAN OUT

# 1

Inset A


11.4 Connecting Stages in a Variable Controller or Controller with PCB 150 to a Relay Panel

V FAN IN V FAN OUTV FAN XT V FAN XT

HH NetAC Power

123456789101112

V FAN IN V FAN OUTV FAN XT V FAN XT

JUMPER

Pressuregnd Sig. 12V

Inset A

Inset B

Remove Stage Jumpers if using a separate power supply for each stage


11.5 Connecting Stages in a Non-variable Controller or Controller with PCB 164 to a Relay Panel

1 2 3 4 5 6 7 8 9 10

11

12

Common From Relay Panel

COMMON


11.6 Connecting AC Power to the Controller

Check Position of the115/230 Volt Selector

Switch

Inset A

Inset A

To BreakerGround

Neutral

Hot

V FAN IN V FAN OUT


11.7 Variable Speed Wiring

Breaker Panel

Inset A

Inset A

V FAN IN V FAN OUT

V FAN IN V FAN OUT

Repeat To Add Additional Fan

HOT

NEUTRAL


11.8 Variable Speed Wiring with External Hookup

c 1994,1995 Hired Hand, Inc.PCB134 (Rev 0) 8 June 1994 M. Calvert

AC

HO

TIN

OUT

POS

CNT

RL

CON

TRO

L IN

MO

NIT

OR

Brea

ker

Pane

lH

ot

Neu

tral

V FAN IN V FAN OUT

# 1

V Fan XT V Fan XT

Inset A

Inset A


11.9 Connecting the Stage Master to a Data Shuttle

V FAN IN V FAN OUT

# 1

gnd HI LO 12V

HH Net

BrownGreen

OrangeOrange/White

Inset A

Inset A


11.10 Connecting the Stage Master to a Series or Parallel Alarm

V FAN IN V FAN OUT

# 1

Inset A

Note: The internal wiring shows the condition of the alarm relay during normal conditions (no alarm present). During an alarm condition, the contact positions will be reversed.

Inset A


12. Program Reference

Program Parameters PSd --Room Temp

Display Default reading displayed in the Main Display.

100 = Sensor 1 020 = Sensor 2 120 = Average of Sensors 1 & 2 003 = Sensor 3 103 = Average of Sensors 1 & 3 023 = Average of Sensors 2 & 3 123 = Average of Sensors 1,2,& 3

P1 -- Stage Sensor The combination of sensors used to determine whether that stage should be on or off.

100 = Stage uses sensor 1 020 = Stage uses sensor 2 120 = Average of sensors 1 & 2 003 = Stage uses sensor 3 103 = Average of sensors 2 & 3 023 = Average of sensors 2 & 3 123 = Average of sensors 1,2,& 3

P2 -- Stage Mode Heat, Cool Negative, etc. This setting determines when the

stage is allowed to run, and how the stage will run. 1 = Heat Mode 2 = Cool Stir Mode 3 = Cool Negative Mode 4 = Cool Negative Tunnel Mode 5 = Cool Tunnel Mode

P3 -- Stage on Timer Any cool stage can be placed on the system timer. This timer is

settable to 5 or 10 minutes. Any stage on a timer will run for the system runtime percentage. (Example: 30% runtime of 10 minutes = 3 minutes out of each ten.)

0 = No Timer 1 = Standard Timer 2 = Cool Timer

ON -- OnPoint The temperature at which a stage will turn on.

OFF -- OffPoint The temperature at which a stage will turn off.

P10 – Minimum Runtime

Percentage If temperature is below the offpoint, the percent of the system timer that the fan will run at it’s minimum speed.

P11 -- Motor Curve Different manufacturers motors speeds vary at different rates. For this reason, it is necessary to make calculations based on the fan manufacturer. 0 = Hired-Hand

P20 -- Cycle Time The length of time in minutes between the start of one curtain position adjustment, and the start of the next curtain position adjustment. (Cycle time of 3 means that the curtain will move up or down (or remain stationary) depending upon temperature for its runtime once every 3 minutes.)


P21 -- Run Time The number of seconds that the curtain machine will run opening or closing at the beginning of each curtain cycle (See Cycle Time).

P22 -- Initial Run Time Number of seconds to run on the first drop from closed. This is to be sure that you have cleared the top of the opening. This setting only applies when the controller senses that the curtain is closed when it begins its run.

P23 -- Degrees above target (Unit 1)

Many times it is more cost effective to bring a slightly high temperature back into range with a fan. This setting allows you to specify a number of degrees above the target temperature that the curtain will allow before trying to open.

P24 -- Degrees above target (Unit 2)

Occasionally, a grower may want one curtain sidewall to drop before the other to try to avoid large temperature swings. This setting allows for this to happen. Note: If you would like both curtain units to always react together, you must set P23=P24.

P25 – Tunnel Onpoint The temperature at which the controller will go into tunnel mode.

P26 -- Tunnel Offpoint The temperature at which the controller will go out of tunnel mode.

P27 -- Close Override The degrees below target at which time the curtains will override to close.

P40 - HHNet Address Unique setting for controllers along a single network wire pair. Only used with the PC compatibility feature using Hired-Hand’s Farm Manager software.

P41 -- Version Number This is the version of the code for the controller. This value is not settable.

P42 -- Controller Type This is a number that identifies the type of controller (Stage Master) to the Farm Manager Software (PC compatible)

PS1 - Calibrate Sensor 1 The temperature the controller reads from the sensor. This setting is used only when calibrating sensors. Press the + and/or - buttons until the correct reading is seen in the main display. (See Sensor Calibration)

PS2 -- Calibrate Sensor 2 Same instructions as sensor PS1




Tunnel Switches (Located inside the Controller Door)

SWX 1 - Tunnel On/Off Enables/Disables tunnel mode When this switch is in the OFF position, the controller will not go into tunnel for any reason.

SWX 2 - Tunnel On Stage Option to have the controller go into tunnel whenever the first tunnel stage turns on. If this switch is OFF, the controller will use the “Tunnel OnPoint” setting for entry into tunnel.

SWX 3 - Power Ventilate If you have a power ventilated house the controller will leave the inlet curtain closed until tunnel mode is entered. This switch must be set to ON if you have a Power Ventilated house.

Status Switches (Located inside the Controller Door)

SWX 1 - Lock Locks the front panel to protect your settings from accidental change. If the switch is set to ON the program settings are locked.

SWX 2 - Fahrenheit or Celsius

Switches the temperature readings from Fahrenheit to Celsius. If the switch is set to ON the controller will read the sensors as Fahrenheit. (Note: If you change this switch, you will have to reset your tunnel OnPoints and OffPoints and your Target Temperature.)

SWX 3 - 5/10 minute timer This switch selects between a 5 and 10 minute system timer. If the switch is on, the timer is 10 minutes.

SWX 4 - Sensor 3 Active When this switch is in the off position, Sensor 3 is turned off. Note: For half house brooding, place Sensor 3 in the non-brooding end of the house, and disable it with this switch when brooding. If the switch is ON, sensor 3 is used.

SWX 5 - Curtains On Separate Sensor

This switch is used to choose whether the curtain machines operate off the same sensor or if they operate independently. If the switch is on, the curtains are independent with curtain 1 running on sensor 1, and curtain 2 running on sensor 2.

SWX 8 - Program ‘A’ or ‘B’

This switch is used to toggle between 2 preset programs. This could be used to store separate summer/winter programs for instance.


13. Error Codes

13.1 Descriptions If your controller is displaying an “E1”, or “E2”, etc. the controller has recorded an error. The controller records errors from sensor readings, and tunnel related problems. To diagnose your controller problem, look up the error on the table (under “Error Codes”) and look across the table to find the components that have failed. ( Items with an “x” have failed according to the controller.)

13.2 Possible Solutions

Sensor Error If any of the sensors are bad try the following: • Reset the controller by taking power away at the breaker, or unplugging it. • Determine which sensor is bad, then check the connection inside the controller door. If

the error is for sensor 3, read the section below to determine alternate course of action. • Determine which sensor is bad, then check the sensor that is hanging in the house to

make sure that it has not been damaged. • Replace the bad sensor.

Sensor 3 Error • Check to see if you are using sensor 3. If not, deactivate it using switch number 4 (SWX-

4) on the status switch bank located on the back of the controller’s door.

Error Sensor 1 Sensor 2 Sensor 3 Sensor 4 TunnelCode Description Error Error Error Error Error

E1 Sensor 1 Error XE2 Sensor 2 Error XE3 Sensor 1 & 2 Error X XE4 Sensor 3 Error XE5 Sensor 1 & 3 Error X XE6 Sensor 2 & 3 Error X XE7 Sensor 1,2 & 3 Error X X XE8 Sensor 4 Error XE9 Sensor 1 & 4 Error X XE10 Sensor 2 & 4 Error X XE11 Sensor 1, 2 & 4 Error X X XE12 Sensor 3 & 4 Error X XE13 Sensor 1, 3, and 4 Error X X XE14 Sensor 2, 3, & 4 Error X X XE15 All Sensors Error X X X XE16 Tunnel Error XE17 Tunnel and Sensor 1 Error X XE18 Tunnel and Sensor 2 Error X XE19 Tunnel and Sensor 1 & 2 Error X X XE20 Tunnel and Sensor 3 Error X XE21 Tunnel and Sensor 1 & 3 Error X X XE22 Tunnel and Sensor 2 & 3 Error X X XE23 Tunnel and Sensor 1,2 & 3 Error X X X XE24 Tunnel and Sensor 4 Error X XE25 Tunnel and Sensor 1 & 4 Error X X XE26 Tunnel and Sensor 2 & 4 Error X X XE27 Tunnel and Sensor 1, 2 & 4 Error X X X XE28 Tunnel and Sensor 3 & 4 Error X X XE29 Tunnel and Sensor 1, 3, and 4 Error X X X XE30 Tunnel and Sensor 2, 3, & 4 Error X X X XE31 Tunnel and All Sensors Error X X X X X


Tunnel Error The controller will error if it can not open the inlet curtain, or if you are using a main curtain it will error if it can not close the main curtain.

Note: If not using a main curtain, you must put a jumper wire across the main curtain closed signal inside the control box.

If you see a tunnel error, check the following: • Make sure that the inlet is operating correctly. • If applicable, make sure the main curtain is operating correctly. • Make sure that the curtain closed signals inside the control box are wired to the

auxiliary switches inside the PowerTrak.

Variable Speed Fans not Operating If the variable speed fans are not operating properly, do the following: • Try a different motor curve (P11). • If the system is using 110 VAC, make sure that the neutral wire is connected to L1, and

the Hot wire is Connected to L2 • Make sure a proper earth ground is connected to the controller.


14. Temperature vs. Sensor Resistance Table The following chart gives the resistance when measured between the white and black sensor wires at a given temperature. To check a sensor, first know the temperature in the area, then, use a multi-meter to check the resistance. Resistance Temp Temp Resistance Temp Temp Resistance Temp Temp

Kohms (F) (C) Kohms (F) (C) Kohms (F) (C)32.654 32 0 15.714 59 15 8.59 83.3 28.532.158 32.5 0.3 15.568 59.4 15.2 8.517 83.7 28.731.671 33.1 0.6 15.353 59.9 15.5 8.408 84 28.931.191 33.6 0.9 15.211 60.3 15.7 8.336 84.6 29.230.72 34.2 1.2 15.001 60.8 16 8.23 85.1 29.5

30.257 34.7 1.5 14.863 61.2 16.2 8.125 85.6 29.829.802 35.2 1.8 14.658 61.7 16.5 8.056 86 3029.355 35.8 2.1 14.457 62.2 16.8 7.954 86.5 30.328.915 36.3 2.4 14.325 62.6 17 7.853 87.1 30.628.482 36.9 2.7 14.128 63.1 17.3 7.787 87.4 30.828.057 37.4 3 13.999 63.5 17.5 7.689 88 31.127.777 37.8 3.2 13.808 64 17.8 7.592 88.5 31.427.363 38.3 3.5 13.682 64.4 18 7.496 89.1 31.726.957 38.8 3.8 13.496 64.9 18.3 7.433 89.4 31.926.557 39.4 4.1 13.373 65.3 18.5 7.34 90 32.226.164 39.9 4.4 13.192 65.8 18.8 7.248 90.5 32.525.777 40.5 4.7 13.073 66.2 19 7.157 91 32.825.523 40.8 4.9 12.896 66.7 19.3 7.098 91.4 3325.147 41.4 5.2 12.779 67.1 19.5 7.009 91.9 33.324.777 41.9 5.5 12.607 67.6 19.8 6.922 92.5 33.624.413 42.4 5.8 12.493 68 20 6.836 93 33.924.055 43 6.1 12.325 68.5 20.3 6.779 93.4 34.123.82 43.3 6.3 12.215 68.9 20.5 6.695 93.9 34.4

23.472 43.9 6.6 12.051 69.4 20.8 6.612 94.5 34.723.13 44.4 6.9 11.943 69.8 21 6.531 95 35

22.793 45 7.2 11.783 70.3 21.3 6.45 95.5 35.322.572 45.3 7.4 11.678 70.7 21.5 6.371 96.1 35.622.244 45.9 7.7 11.522 71.2 21.8 6.319 96.4 35.821.922 46.4 8 11.42 71.6 22 6.241 97 36.121.71 46.8 8.2 11.268 72.1 22.3 6.165 97.5 36.4

21.397 47.3 8.5 11.168 72.5 22.5 6.089 98.1 36.721.088 47.8 8.8 11.02 73 22.8 6.015 98.6 3720.886 48.2 9 10.874 73.6 23.1 5.941 99.1 37.320.586 48.7 9.3 10.778 73.9 23.3 5.869 99.7 37.620.29 49.3 9.6 10.636 74.5 23.6 5.798 100.2 37.9

20.096 49.6 9.8 10.542 74.8 23.8 5.728 100.8 38.219.809 50.2 10.1 10.404 75.4 24.1 5.658 101.3 38.519.526 50.7 10.4 10.312 75.7 24.3 5.59 101.8 38.819.34 51.1 10.6 10.177 76.3 24.6 5.522 102.4 39.1

19.065 51.6 10.9 10.088 76.6 24.8 5.456 102.9 39.418.884 52 11.1 9.956 77.2 25.1 5.39 103.4 39.718.616 52.5 11.4 9.869 77.5 25.3 5.326 104 4018.352 53.1 11.7 9.741 78.1 25.6 5.262 104.5 40.318.179 53.4 11.9 9.614 78.6 25.9 5.199 105.1 40.617.503 54.9 12.7 9.53 79 26.1 5.137 105.6 40.917.339 55.2 12.9 9.407 79.5 26.4 5.076 106.2 41.217.095 55.8 13.2 9.325 79.9 26.6 4.995 106.9 41.616.856 56.3 13.5 9.205 80.4 26.9 4.936 107.4 41.916.698 56.7 13.7 9.086 81 27.2 4.877 108 42.216.465 57.2 14 9.007 81.3 27.4 4.82 108.5 42.516.312 57.6 14.2 8.891 81.9 27.7 4.763 109 42.816.085 58.1 14.5 8.815 82.2 27.9 4.688 109.8 43.215.935 58.5 14.7 8.702 82.8 28.2


15. Program Parameter Listing


16. Error Code Listing

Error Sensor 1 Sensor 2 Sensor 3 Sensor 4 TunnelCode Description Error Error Error Error Error

E1 Sensor 1 Error XE2 Sensor 2 Error XE3 Sensor 1 & 2 Error X XE4 Sensor 3 Error XE5 Sensor 1 & 3 Error X XE6 Sensor 2 & 3 Error X XE7 Sensor 1,2 & 3 Error X X XE8 Sensor 4 Error XE9 Sensor 1 & 4 Error X XE10 Sensor 2 & 4 Error X XE11 Sensor 1, 2 & 4 Error X X XE12 Sensor 3 & 4 Error X XE13 Sensor 1, 3, and 4 Error X X XE14 Sensor 2, 3, & 4 Error X X XE15 All Sensors Error X X X XE16 Tunnel Error XE17 Tunnel and Sensor 1 Error X XE18 Tunnel and Sensor 2 Error X XE19 Tunnel and Sensor 1 & 2 Error X X XE20 Tunnel and Sensor 3 Error X XE21 Tunnel and Sensor 1 & 3 Error X X XE22 Tunnel and Sensor 2 & 3 Error X X XE23 Tunnel and Sensor 1,2 & 3 Error X X X XE24 Tunnel and Sensor 4 Error X XE25 Tunnel and Sensor 1 & 4 Error X X XE26 Tunnel and Sensor 2 & 4 Error X X XE27 Tunnel and Sensor 1, 2 & 4 Error X X X XE28 Tunnel and Sensor 3 & 4 Error X X XE29 Tunnel and Sensor 1, 3, and 4 Error X X X XE30 Tunnel and Sensor 2, 3, & 4 Error X X X XE31 Tunnel and All Sensors Error X X X X X


17. Curtain Movement Time (sec.) Vs. Distance (inches/cm.) To find the distance moved, select the chart corresponding to a specific Motor Speed and Cabling Ratio.

NOTE: Cabling Ratio = First number is PT and second number is load. Motor RPM Cabling Ratio Seconds Inches Centimeters

5 0.25 0.635 10 0.50 1.27 15 0.75 1.905 30 1.5 3.81 45 2.25 5.715

1 to 1

60 3 7.652 5 0.5 1.27 10 1.0 2.54 15 1.5 3.81 30 3.0 7.62 45 4.5 11.43

1 to 2

60 6.0 15.24 5 0.125 0.3175 10 0.25 0.635 15 0.375 0.9525 30 0.75 1.905 45 1.125 2.875

15

2 to 1

60 1.5 3.81 5 0.5 1.27 10 1.0 2.54 15 1.5 3.81 30 3.0 7.62 45 45.5 11.43

1 to 1

60 6.0 15.24 5 1 2.54 10 2 5.08 15 3 7.62 30 6 15.24 45 9 22.86

1 to 2

60 12 30.48 5 0.25 0.635 10 0.50 1.27 15 0.75 1.905 30 1.5 3.81 45 2.25 5.715

30

2 to 1

60 3 7.652 5 1 2.54 10 2 5.08 15 3 7.62 30 6 15.24 45 9 22.86

1 to 1

60 12 30.48 5 2 5.08 10 4 10.16 15 6 15.24 30 12 30.48 45 18 45.72

1 to 2

60 24 60.96 5 0.5 1.27 10 1.0 2.54 15 1.5 3.81 30 3.0 7.62 45 45.5 11.43

60

2 to 1

60 6.0 15.24


18. Program Data Sheet Use this Data Sheet to record your personal settings for the Stage Master. Copy this form as needed.

Status Switches Tunnel Switches Target Swx 1 Lock On/Off Swx 1 Tunnel On On/Off

V1 Min. Speed Swx 2 Unit On-Far./Off Cel. Swx 2 Initiate On-Stage/Off-Outside V2 Min. Speed Swx 3 Timer On-10/Off-5 Swx 3 House Style On-Power/Off-Natural

Timer % Swx 4 Sensor 3 On/Off Swx 4 Unused PSD Swx 5 Curtains On-SS/Off-Avg.

Swx 6 Unused Swx 7 Unused Swx 8 Program On-B/Off-A

Stages

Equipment

OnPoint

OffPointP1

Sensors P2

Mode P3

Timer P10

Runtime%

P11 Motor Curve

1 2 3 4 5 6 7 8 9

10 11 12

P20 Curtain Cycle Time Min. Network Address P40

P21 Curtain Runtime Sec. Software Version P41

P22 Curtain Initial Runtime Sec. Controller Setup P42

P23 Unit 1 DAT Cool Timer Max. % P70

P24 Unit 2 DAT Cool Time Min. % P71

P25 Tunnel “On” Temp

P26 Tunnel “Off” Temp P27 Close Override

P1 Sensors P2 Mode P3 Timer 100=Sensor 1 1=Heat 0=Off Timer 020=Sensor 2 2=Cool Stir 1=On Normal Timer 120=Avg. Sen 1&2 3=Cool Neg 2=On Cool Timer 003=Sensor 3 4=Cool Neg Tunnel 103=Avg. Sen 1&3 5=Cool Tunnel 023=Avg. Sen 2&3 123=Avg. Sen 1,2&3 (Version 15 or above)

FFaarrmm HHaanndd SSttaaggee MMaasstteerr

Documents

Farm Hand Stage Masteresvc000637.wic056u.server-web.com/manuals/4801-0151 Farm... · 2008-10-03 · Part No. 4801-0151 Rev 8-04 Farm Hand Stage Master 6 of 39 Var/Timer Percentage